Safety alert follows discovery that fuel switches were flipped to cutoff during fatal Air India flight

Etihad Airways has issued an urgent advisory to its Boeing 787 pilots following a preliminary investigation into the deadly Air India crash in Ahmedabad. The report revealed that both fuel control switches on the aircraft moved from the “RUN” to “CUTOFF” position just seconds after take-off, leading to a complete shutdown of both engines and the loss of all 260 lives on board.

Etihad’s bulletin, released July 12—the same day the crash report was made public—urges pilots to handle the fuel switches with caution and directs engineers to inspect the fuel switch locking mechanism across its 787 fleet. The airline described the move as a measure taken “out of an abundance of caution.”

South Korea is also reportedly preparing a similar directive for its own airlines operating Boeing aircraft, highlighting growing global concern around cockpit control reliability on the 787 and potentially other Boeing models.

What did the Air India crash report uncover?

India’s Aircraft Accident Investigation Bureau (AAIB) published its preliminary findings on July 12, exactly one month after the Air India flight went down. The aircraft, a Boeing 787, crashed shortly after take-off from Ahmedabad.

According to the report:

• Both fuel switches flipped from “RUN” to “CUTOFF” within seconds of take-off
• Both engines shut down mid-air, leading to a complete power loss
• The switches were manually operated or triggered unintentionally
• A cockpit voice recording captured one pilot saying, “Why did you cut off?” and the other replying, “I didn’t.”

The report did not definitively conclude whether the switches were accidentally bumped, malfunctioned, or were part of a deeper design flaw. It did, however, reference a 2018 FAA advisory that warned operators to inspect the locking mechanism of fuel switches across Boeing aircraft.

Etihad’s new flight deck protocols

Following the report, Etihad issued an internal bulletin to its flight crews and maintenance staff outlining new safety protocols:

• Pilots are advised to exercise caution when operating the fuel control switches or any controls nearby.
• Crews are instructed to avoid placing any loose objects on the cockpit pedestal, the area where the switches are located.
• Engineers are directed to inspect the locking mechanisms on all Boeing 787 fuel switches to ensure proper engagement.
• Any unusual behavior or movement involving the switches must be immediately reported and documented.

While the aircraft’s design includes a locking feature meant to prevent accidental activation of the switches, the crash has called into question how reliably this feature performs during normal operations.

South Korea takes notice

According to a Reuters report, South Korea’s Ministry of Land, Infrastructure and Transport is preparing a mandate for airlines operating Boeing aircraft to conduct safety inspections of the fuel control systems. While no timeline has been announced, the move is expected to align with global efforts to reassess the safety of cockpit switch design and pilot interaction.

Boeing and FAA respond

In a joint notice to global aviation authorities, Boeing and the US Federal Aviation Administration acknowledged the safety concerns raised in the crash report. However, they maintained that the issue does not currently warrant an airworthiness directive.

The FAA’s statement read:

“Although the fuel control switch design, including the locking feature, is similar on various Boeing airplane models, the FAA does not consider this issue to be an unsafe condition that would warrant an Airworthiness Directive on any Boeing airplane models, including the Model 787.”

This response has raised some eyebrows, particularly in light of previous Boeing-related safety controversies. Still, most regulators appear to be moving forward with individual airline or country-specific inspections rather than waiting for broader FAA action.

Why are fuel switches so crucial?

The fuel control switches in a Boeing 787 are responsible for regulating fuel supply to the aircraft’s engines. During normal operations, they are placed in the “RUN” position. Moving them to “CUTOFF” shuts off fuel flow and stops the engine.

These switches are designed with locking features to prevent accidental activation. But as the Air India incident suggests, even a momentary lapse—whether due to poor design, human error, or unintended contact—can trigger catastrophic outcomes.

The 2018 FAA advisory that resurfaced in the crash report specifically recommended operators verify that locking features are correctly installed and functioning. The Air India report suggests this check may not have been uniformly enforced across fleets.

What’s at stake for airlines?

The swift actions by Etihad and the anticipated moves by South Korea suggest airlines are not waiting for federal directives. Instead, they are taking proactive steps to review cockpit ergonomics and ensure that basic safety mechanisms like locking switches are not left to chance.

The stakes are high:

• Any misstep with cockpit controls can lead to a loss of life
• Airlines risk public trust if preventable mechanical oversights are ignored
• Boeing’s long-term credibility is again under scrutiny, following prior issues with its 737 MAX program

Inspections and procedural updates now may prevent future disasters and help restore confidence in aircraft safety.

What can passengers take away from this?

For travelers, the key takeaway is that modern aviation is built on multiple layers of safety. But when a single mechanical detail—like the position of a switch—can bring down a commercial airliner, it becomes clear how critical system integrity really is.

The Air India crash has raised serious concerns, but it has also prompted swift and transparent action from major carriers. Whether it leads to long-term design changes or only temporary operational guidelines remains to be seen.

Still, Etihad’s message is clear: better to act early than wait for a repeat.

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